Structural reinforcement member for wheel well

ABSTRACT

A structural reinforcement member for reinforcing a wheel well area of an automobile includes a carrier and a load distributing medium supported by the carrier. The carrier also may include a reinforced protrusion, two reinforced openings, and an outwardly extending flange. The flange includes a reinforced raised portion having a shape similar to that of the flange. The load distributing medium is a structural foam and preferably an epoxy-based resin. The preferred load distributing medium is L5206, L5207, L5208, or L5209 structural foam commercially available from L&amp;L Products of Romeo, Mich.

FIELD OF THE INVENTION

[0001] The present invention relates generally to a structuralreinforcement member for use in increasing the stiffness and strength ofa frame assembly, such as an automobile frame. More particularly, theinvention relates to a reinforcement member that reinforces the frameusing a heat-activated structural foam, and carrier wherein thecomposite of the carrier and activated foam increases the structuralstiffness and strength of the frame.

BACKGROUND OF THE INVENTION

[0002] For many years the automobile industry has been concerned withdesigning frame reinforcement members that do not add significantly tothe weight of the automobile. U.S. Pat. Nos. 5,755,486; 4,901,500; and4,751,249 describe prior art reinforcing devices. While these prior artdevices may be advantageous in some circumstances, there is needed asimple low cost structure that permits coupling the reinforcement memberto a variety of structures of varying geometric configurations.

SUMMARY OF THE INVENTION

[0003] The present invention is directed to a structural reinforcementmember designed for reinforcing a wheel well portion of an automobileframe. The reinforcement member includes a polymeric carrier, which maybe amenable to injection molding or other such moldable material such aspolymeric, metallic, or ceramic, and a load distributing medium disposedon the carrier. In one embodiment, the carrier supports a reinforcedprotrusion and two reinforced openings. Additionally, the carriersupports an outwardly extending flange. The flange includes a reinforcedraised portion having a shape similar to that of the flange. The loaddistributing medium disposed on the carrier is a structural foam, and ispreferably an epoxy-based resin. The preferred load distributing mediumis L5206, L5207, L5208, or L5209 structural foam, which is commerciallyavailable from L&L Products of Romeo, Mich.

[0004] During an automobile assembly process the reinforcement member ispositioned against the automobile frame so that the uncured structuralfoam is against the wheel well portion. Once the foam is cured, thereinforcement member adheres to the frame and distributes any loads thatimpact the wheel well portion of the automobile frame.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The features and inventive aspects of the present invention willbecome more apparent upon reading the following detailed description,claims, and drawings, of which the following is a brief description:

[0006]FIG. 1 is a front perspective view of a structural reinforcementmember.

[0007]FIG. 2 is a front elevational view of the structural reinforcementmember shown in FIG. 1.

[0008]FIG. 3 is a rear elevational of the structural reinforcementmember shown in FIG. 1.

[0009]FIG. 4 shows a top plan view of the structural reinforcementmember shown in FIG. 1.

[0010]FIG. 5 shows an assembly view of the structural reinforcementmember of FIG. 1 installed in the wheel well portion of an automobileframe.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0011]FIG. 1 shows a structural reinforcement member 10 formed inaccordance with the teachings of this invention. The reinforcementmember 10 includes a carrier 12 and a load distributing medium 14supported by the carrier 12.

[0012] The carrier 12 can be formed of a polymeric material, a preferredpolymeric material being nylon, but may also consist of a metallic orceramic material. More preferably the nylon material is a thirty-threepercent glass filled nylon. However, it will be appreciated that othermaterials having similar properties may be used.

[0013] One advantage of the carrier 12 being fabricated of a moldablematerial is the ability to mold the carrier 12 into a variety ofconfigurations. Specifically, the carrier 12 can be fabricated using amold having virtually the same configuration as the frame portion towhich the reinforcement member 10 will be coupled. This facilitatesassembling the reinforcement member 10 with the automobile frame withoutthe need for mechanical fasteners or welding.

[0014] The carrier 12 is a four-sided structure having a squareconfiguration, and includes a front surface 16, an opposing rear surface18, and opposing side surfaces 20. It will be appreciated that othersuitable geometric configurations may be used to form the carrier 12.For example, the carrier 12 may be rectangular, circular, or a varietyof complex geometrical configurations. The particular configurationchosen for the carrier 12 will vary depending on the configuration ofthe area being reinforced.

[0015] In the disclosed embodiment, the front surface 16 is surroundedby opposing sides 20 and rear surface 18, wherein the rear surface 18 isreinforced by a lattice network 31. The front surface 16 supports araised circular protrusion 28 that is also reinforced by a latticenetwork 26. It is contemplated that the lattice network 26 may consistof a matrix type design which provides nearly the same level ofreinforcement as a solid structure. Adjacent the protrusion 28, thelower portion 23 of the front surface 16 supports and is reinforced by alattice structure 30. The front surface 16 also includes a pair ofreinforced openings 32, and an integrally formed flange 22. The flange22 projects outwardly from an end portion of the front surface 16 alonga radius 17 formed at a location adjacent one of the opposing sides 20.

[0016] The flange 22 supports an outward projection 34. The flange 22also includes an upper portion 40, which tapers to a narrower strip 42that projects outwardly from and extends along the outer perimeter ofthe flange 22. The outward projection 34 supports a lattice portion 36having a configuration virtually similar to that of the outwardprojection 34.

[0017] The structural strength and stiffness of the carrier 12 isincreased by applying the load distributing medium 14 to selectedsurfaces of the carrier member 12. In the preferred embodiment, the loaddistributing medium 14 is a structural foam applied to the front surface16. The structural foam 14 increases the strength and structuralstiffness of the carrier 12 without adding significantly to the overallweight of the carrier 12. Typically, the structural foam 14 is appliedto the carrier 12 in the areas corresponding to frame areas wherereinforcement is desired such as a continuous load transfer medium orbonding surface application. In the embodiment shown, the structuralfoam 14 is applied to the top surface 20 and the sidewall 18.

[0018] The structural foam 16 is preferably heat-activated and expandsupon heating, typically by a foaming reaction. The structural foam 14 isgenerally applied to the carrier 12 in a solid or semi-solid state. Thestructural foam 14 may be applied to the outer perimeter of the carrier12 in a fluid state using commonly known injection techniques, whereinthe structural foam 14 is heated to a temperature that permits thestructural foam 14 to flow slightly. Upon cooling the structural foam 14hardens and adheres to the outer surface of the carrier 12, either via aseparate adhesive layer (not shown) or via adhesive characteristics inthe structural foam 14 formulation itself. Alternatively, the structuralfoam 14 may be applied to the carrier 12 as precast pellets, which areheated slightly to permit the pellets to bond to the outer surface ofthe carrier 12. At this stage, the structural foam 14 is heated justenough to cause the structural foam 14 to flow slightly, but not enoughto cause the structural foam 14 to expand. Note that other expandablematerials can be used, such as, without limitation, an encapsulatedmixture of materials that, when activated by temperature, pressure,chemically, or other by other ambient conditions, will expand.

[0019] The structural foam 14 is preferably an epoxy-based material, butmay include other polymers such as ethylene copolymers or terpolymers. Acopolymer or terpolymer, is composed of two or three different monomers,i.e., small molecules with high chemical reactivity that are capable oflinking up with similar molecules.

[0020] A number of epoxy-based structural reinforcing foams are known inthe art and may also be used to produce the structural foam 14. Atypical structural foam includes a polymeric base material, such as anepoxy resin or ethylene-based polymer which, when compounded withappropriate ingredients (typically a blowing agent and curing agent),expands and cures in a reliable and predicable manner upon theapplication of heat or the occurrence of a particular ambient condition.The resulting material has a density that is sufficient to impartdesired rigidity to a supported article. From a chemical standpoint fora thermally-activated material, the structural foam 14 is usuallyinitially processed as a thermoplastic material before curing. Aftercuring, the structural foam 14 typically becomes a thermoset material.

[0021] An example of a preferred structural foam 14 formulation is anepoxy-based material including an ethylene copolymer or terpolymer andan alpha-olefin that is commercially available from L&L Products ofRomeo, Mich., under the designations L5206, L5207, L5208 and L5209. Oneadvantage of the preferred structural foam materials 14 over prior artmaterials is that the preferred materials can be processed in severalways. The preferred materials can be processed by injection molding,extrusion or with a mini-applicator type extruder. This enables theformulation and creation of part designs that exceed the capability ofmost prior art materials.

[0022] While the preferred materials for fabricating the structural foam14 have been disclosed, the structural foam 14 can be formed of othermaterials provided that the material selected is heat-activated orotherwise activated by an ambient condition (e.g. moisture, pressure,time or the like) and expands in a predictable and reliable manner underappropriate conditions for the selected application. Some other possiblematerials include, but are not limited to, polyolefin materials.Copolymers and terpolymers with at least one monomer type analpha-olefin, phenol/formaldehyde materials, phenoxy materials, andpolyurethane materials with high glass transition temperatures. Seealso, U.S. Pat. Nos. 5,766,719; 5,755,486; 5,575,526; and 5,932,680, thedisclosures of which are incorporated herein by reference. In general,the desired characteristics of the structural foam 14 include highstiffness, high strength, high glass transition temperature (typicallygreater than 70 degrees Celsius), and good corrosion resistanceproperties.

[0023] In applications where a heat activated, thermally expandingmaterial is employed, an important consideration involved with theselection and formulation of the material comprising the structural foam14 is the temperature at which a material reaction or expansion, andpossibly curing, will take place. For instance, in most applications, itis undesirable for the material to be reactive at room temperature orotherwise at the ambient temperature in a production line environment.More typically, the structural foam 14 becomes active at higherprocessing temperatures, such as those encountered in an automobileassembly plant, when the foam 14 is processed along with the automobilecomponents at elevated temperatures or at higher applied energy levels.While temperatures encountered in an automobile assembly operation maybe in the range of 148.89° C. to 204.44° C. (300° F. to 400° F.), bodyand paint shop applications are commonly about 93.33° C. (200° F.) orslightly higher. Generally, prior art expandable foams have a range ofexpansion ranging from approximately 0 to over 1000 percent. The levelof expansion of the structural foam 14 may be increased to as high as1500 percent or more. Higher expansion, now ever, typically results inmechanical property reduction.

[0024] The reinforcement member 10 may be used in numerous applicationswhere structural reinforcement is desired. More particularly, thereinforcement member 10 has particular application in those instanceswhere the overall weight of the structure being reinforced is a criticalfactor. For example, the reinforcement member 10 may be used toreinforce the frames of automobiles, airplanes, boats, buildingstructures and other similar objects.

[0025]FIG. 5 illustrates the reinforcement member 10 being installed ina wheel well portion 44 of an automobile frame 46. As can be seen in thefigure, the reinforcement member 10 fits against the wheel well portion44 so that the load distributing medium 14 is in contact with the frame46. The load distributing medium 14 is then cured in the course of theautomotive assembly process.

[0026] Once the load distributing medium 14 is cured, the structuralfoam 14 expands along the front surface 16 and fills the gap 46surrounding the circular protrusion 28. When placed adjacent a structureto be reinforced, i.e., the wheel well 44, the cured structural foamacts as an adhesive and thus bonds the reinforcement member 10 to theelement being reinforced.

[0027] The structural foam 14 is fully cured by subjecting thereinforcement member 10 to temperatures in the range of those generatedby a paint oven of the type used to cure automobile body paint orprimer. It will be appreciated that paint ovens are known to reachminimum temperatures of 93.33° C. (200° F.) or greater. Thus, it will beappreciated that the structural foam 14 may be cured by simply heatingthe reinforcement member 10 to a temperature of 93.33° C. (200° F.) orgreater.

[0028] The curing of the structural from 14 increases the structuralstrength and stiffness of the carrier 12. As a result, the overallstructural strength and stiffness of the reinforcement member 10 isincreased.

[0029] The preferred embodiment of the present invention has beendisclosed. A person of ordinary skill in the art would realize, however,that certain modifications would come within the teachings of thisinvention. Therefore, the following claims should be studied todetermine the true scope and content of the invention.

What is claimed is:
 1. A structural reinforcement member for reinforcinga wheel well portion of an automobile frame, comprising: a carrieradapted to fit in a wheel well portion of an automobile frame, thecarrier having a front surface and a rear surface; and a loaddistributing medium supported by the carrier.
 2. The structuralreinforcement member of claim 1, wherein the carrier includes areinforced protrusion on the front surface.
 3. The structuralreinforcement member of claim 1, wherein the carrier supports anoutwardly extending flange.
 4. The structural reinforcement member ofclaim 1, wherein the carrier comprises a polymeric material havingmoldable characteristics.
 5. The structural reinforcement member ofclaim 1, wherein the carrier is comprised of nylon.
 6. The structuralreinforcement member of claim 1, wherein the load distributing medium isa structural foam.
 7. The structural reinforcement member of claim 6,wherein the structural foam is a curing agent.
 8. The structuralreinforcement member of claim 6, wherein the structural foam is formedfrom an epoxy-based resin.
 9. The structural reinforcement member ofclaim 8, wherein the structural foam is L5204 structural foamcommercially available from L&L Products of Romeo, Mich.
 10. Thestructural reinforcement member of claim 8, wherein the structural foamis L5206 structural foam commercially available from L&L Products ofRomeo, Mich.
 11. The structural reinforcement member of claim 8, whereinthe structural foam is L5207 structural foam commercially available fromL&L Products of Romeo, Mich.
 12. The structural reinforcement member ofclaim 8, wherein the structural foam is L5208 structural foamcommercially available from L&L Products of Romeo, Mich.
 13. Thestructural reinforcement member of claim 8, wherein the structural foamis L5209 structural foam commercially available from L&L Products ofRomeo, Mich.
 14. A structural reinforcement member for reinforcing awheel well portion of an automobile frame, comprising: a carrier adaptedto fit in the wheel well portion, the carrier having a front surface anda rear surface; an outwardly extending flange supported by the carrier;a reinforced protruding portion extending from the front surface; astructural foam layer supported by the front surface of the carrier forabsorbing energy.
 15. The structural reinforcement member of claim 14,wherein the structural foam is formed from an epoxy-based resin.
 16. Thestructural reinforcement member of claim 14, wherein the structural foamcomprises a polymeric material having curing agent characteristics. 17.The structural reinforcement member of claim 15, wherein the structuralfoam is L5204 structural foam commercially available from L&L Productsof Romeo, Mich.
 18. The structural reinforcement member of claim 15,wherein the structural foam is L5206 structural foam commerciallyavailable from L&L Products of Romeo, Mich.
 19. The structuralreinforcement member of claim 15, wherein the structural foam is L5207structural foam commercially available from L&L Products of Romeo, Mich.20. The structural reinforcement member of claim 15, wherein thestructural foam is L5208 structural foam commercially available from L&LProducts of Romeo, Mich.
 21. The structural reinforcement member ofclaim 15, wherein the structural foam is L5209 structural foamcommercially available from L&L Products of Romeo, Mich.
 22. Thestructural reinforcement member of claim 14, wherein the front surfaceis supported by a lattice structure.
 23. The structural reinforcementmember of claim 14, wherein the front surface is reinforced by a latticenetwork.
 24. A method for reinforcing a wheel well portion of anautomobile frame, comprising the steps of: providing a structural membercontaining the wheel well portion; coupling a reinforcement member tothe wheel well portion of the structural member, wherein thereinforcement member includes a carrier and a load distributing mediumsupported by the carrier; and activating the load distributing medium bychanging a predetermined ambient condition.